Single shot injection molded article

ABSTRACT

Disclosed herein is a baffle for regulating air flow around an object. The baffle can be of unitary construction and can be made by a single shot injection molding process. The baffle can have an edge portion that is more flexible than the base portion. The baffle has also can have a base portion with a base portion thickness and an edge portion with an edge portion thickness that is less than the base portion thickness. A method of making a baffle by an injection molding process is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Non-Provisional applicationSer. No. 15/474,540, filed on Mar. 30, 2017, which is herebyincorporated by reference in its entirety.

BACKGROUND

The present disclosure relates to baffles and methods of making them.More particularly, the disclosure relates to a baffle, such as aradiator baffle, which is made by a single-shot injection moldingprocess, and which has increased flexibility at its sealing edge andthereby avoids a crash condition when in use.

In many mechanical contexts, including the radiator of a vehicle,control of air circulation assists in proper operation of a component.Baffles can function to divert air flow such that it either is guidedinto, or is kept out of, a particular area. Additionally, in mechanicalarchitectures where parts are spaced to fit together without colliding,but air flow management and gap filling are still required, baffles canbe used to fill spaces and meet manufacturing tolerances.

Typically, baffles having flexible edges are produced by joiningseparate materials having different flexibilities. The two componentsare attached together in a two-shot process to form the baffle, in someinstances by an attachment process such as sonic welding, attaching arelatively flexible material to one which is relatively stiffer. Suchbaffles, however, may not provide a good seal owing to their lowerflexibility. Further, the process is labor-intensive owing to multiplesteps, and has a relatively high cost due to the additional labor andexpensive tooling.

It has been a challenge to develop an economical method of producingbaffles that provide good sealing and flexibility.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to a baffle for regulating air flow aroundan object. The baffle may be of unitary construction and can be made ina single shot injection molding process.

In one embodiment, the baffle includes a base portion and an edgeportion for contacting surface of the object. The base portion and theedge portion may be of unitary construction. The base portion may have abase portion thickness, and the edge portion may have an edge portionthickness that is less than the base portion thickness. The edge portionmay have a first edge portion thickness proximal to the base portion andmay taper away from the base portion to a second edge portion thicknessdistal to the base portion that is less than the first edge portionthickness.

In another embodiment, the baffle may include a base portion and an edgeportion connected to the base portion at a junction. The base portionand the edge portion may be of unitary construction. The base portionmay have a first thickness at the junction, and the edge portion mayhave a second thickness less than the first thickness at the junction.

In another embodiment, the baffle comprises a base portion and an edgeportion for contacting the surface of the object. The base portion andthe edge portion may be of unitary construction. The edge portion may bemore flexible than the base portion. For example, the base portion mayhave a first flexural modulus, and the edge portion may have a secondflexural modulus, where the first flexural modulus is greater than thesecond flexural modulus.

In some embodiments, the edge portion of the baffle preferentiallydeforms in a defined direction when the edge portion is placed incontact with the surface of the object to impart directionalflexibility.

In another embodiment, a method of making the baffle for regulating airflow around an object is disclosed. The method may include a single shotinjection molding step comprising injecting a single material in amolten state into a mold and allowing the material to solidify to form abaffle comprising a base portion and an edge portion, the base portionhaving a base portion thickness, and the edge portion having an edgeportion thickness that is less than the base portion thickness. Thematerial may be a polymer, such as polypropylene.

Further aspects, features, and advantages of the invention will becomeapparent from consideration of the following description and theappended claims when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective view of a unitary baffle constructed in accordancewith the principles of the present disclosure;

FIG. 2 is a cross-sectional view of the baffle of FIG. 1;

FIG. 3 is a side view of a baffle constructed in accordance with theprinciples of the present disclosure, shown in a nominal condition witha mating component;

FIG. 4 is a side view of the baffle and mating component of FIG. 3,shown instead in a crash configuration;

FIG. 5 is a cross-sectional view of another embodiment of a baffleillustrating a step down in thickness at the seal;

FIG. 6 is a cross-sectional view of another embodiment of a baffleillustrating a step down in thickness without a curved portion;

FIG. 7 is a cross-sectional view of another embodiment of a baffleillustrating a taper in thickness and without a curved portion; and

FIGS. 8-10 are graphical representations of the results ofcompression/deflection tests on a variety of baffles.

DETAILED DESCRIPTION OF THE INVENTION

The following provides a detailed description of several embodiments ofthe present invention. The description is not intended to limit theinvention in any manner, but rather serves to enable those skilled inthe art to make and use the invention.

The present disclosure relates to a baffle for regulating air flowaround an object, the baffle comprising a base portion and an edgeportion for contacting a surface of the object, the base portion and theedge portion being of unitary construction, the base portion having abase portion thickness, and the edge portion having an edge portionthickness that is less than the base portion thickness such that theedge portion is capable of deforming to mate with the surface of theobject while the base portion remains substantially rigid.

The present disclosure also relates to a baffle for regulating air flowaround an object, the baffle comprising a base portion and an edgeportion for contacting a surface of the object, the base portion and theedge portion being of unitary construction, wherein the edge portion ismore flexible than the base portion such that the edge portion iscapable of deforming to mate with the surface of the object while thebase portion remains substantially rigid. In some embodiments, the baseportion has a first flexural modulus, and the edge portion has a secondflexural modulus that is less than the first flexural modulus. In someembodiments, the second flexural modulus is about 10% to about 95% ofthe first flexural modulus, or about 20% to about 75% of the firstflexural modulus, or about 25% to about 50% of the first flexuralmodulus, or about 30% of the first flexural modulus.

As used herein, the phrase “unitary construction” refers to an objectmade up of a single, homogeneous body of material, without seams orjoints.

A used herein, the phrase “edge portion thickness” refers to thethickness of the edge portion of the baffle. Where the edge portion of abaffle does not have a uniform thickness, the baffle will be understoodto have multiple edge portion thicknesses. The edge portion thickness ofa baffle will be understood to be less than the base portion thicknessif the mean edge portion thickness is less than the base portionthickness. Likewise, where the edge portion thickness is expressed as apercentage of the base portion thickness, the percentage refers to themean edge portion thickness.

As used herein, the phrase “base portion thickness” refers to the meanthickness of the base portion of the baffle.

Referring to FIG. 1, a baffle 10 constructed according to the principlesof the present invention is depicted. The baffle 10 may include a baseportion 20 which is substantially planar and may constitute the largestportion of the baffle 10. The baffle may include a first connectingportion 12 and a second connecting portion 14 for securing the baffle 10in the position in which it is to operate (for instance, to a side or abottom of a radiator). The baffle may include at least one tab 16 forincreased stability in placement of the baffle 10 by providing anadditional point of contact between the baffle 10 and the assembly towhich it is connected.

The baffle 10 also includes an edge portion 22, which may function toform a seal with another object. In the illustrated embodiment, the edgeportion 22 extends away from the base portion 20 to form a sealingportion of the baffle 10. The edge portion is capable of deforming tomate with the surface of the object while the base portion remainssubstantially rigid.

FIG. 2 shows a cross-sectional view along line 2-2 of the baffle 10 andfurther illustrates features of the embodiment shown in FIG. 1. The baseportion 20 extends from a first end 24 to a junction 38. It will beunderstood that, where the baffle 10 is of unitary construction, thejunction 38 simply refers to the location where the base portion 20 endsand the edge portion 22 begins. The base portion 20 has a base portionthickness d1. Although the base portion 20 is illustrated in thisembodiment as having a substantially uniform thickness, it will beappreciated that the base portion 20 may be selected to have anon-uniform thickness according to the need served by such a component.The edge portion 22 of the baffle 10 extends from the junction 38 and tothe second end 26. The baffle 10 depicted in FIG. 2 has first and secondmajor surfaces 11 a and 11 b. The major surfaces are substantiallycontinuous at the junction 38.

In some embodiments, the edge portion is tapered such that the edgeportion thickness comprises a first edge portion thickness proximal tothe base portion and a second edge portion thickness distal to the baseportion that is less than the first edge portion thickness. In theembodiment illustrated in FIG. 2, the edge portion 22 includes a taperedportion 30, where the thickness of the edge portion 22 decreases betweenthe junction 38 and a point 33 along its length. In some embodiments,the tapered portion 30 may continue all the way to the second end 26. Inother embodiments, the tapered portion 30 may extend only part of theway along the length of the edge portion 22, such that there exists aportion of substantially uniform thickness toward the second end 26 ofthe edge portion 22.

The tapered portion 30 results in the edge portion 22 having adecreasing edge portion thickness as measured from the junction 38 andaway from the base portion 20. At a particular point away from the baseportion 20, the edge portion 22 may have an edge portion thickness d2which is less than the base portion thickness d1. Overall, an edgeportion 22 which includes a single tapered portion 30 may decrease inthickness from a first edge portion thickness to a second edge portionthickness at the second end 26, the second edge portion thickness beingless than the first edge portion thickness.

In one embodiment, the tapered portion 30 may decrease in thickness at asubstantially constant rate, such that the edge portion 22 tapers in asubstantially linear fashion. Depending on the need fulfilled by thebaffle 10, the edge portion thickness may be about 20% to about 75% ofthe measure of the base portion thickness, or about 25% to about 60% ofthe measure of the base portion thickness, or about 30% to about 50% ofthe measure of the base portion thickness. In one embodiment, the edgeportion thickness may be about 30% of the measure of the base portionthickness. In another embodiment, the edge portion thickness may beabout 50% of the measure of the base portion thickness. In an embodimentwhere the baffle 10 is a radiator baffle for an automobile, d2 (asmeasured at the second end 26 of the baffle 10) may be about 0.5millimeters, and d1 (as measured in the base portion 20) may about 2millimeters, where d2 represents the thinnest portion of the baffle 10.It will be appreciated that the values of d1 and d2 as disclosed hereinare only exemplary, and baffles of different sizes and for differentpurposes may have a number of different thicknesses and still fallwithin the scope of the present disclosure.

It will be appreciated that in certain embodiments, the quantity d2recited may not represent the thinnest portion of the edge portion 22.

In some embodiments, the edge portion of the baffle preferentiallydeforms in a defined direction when the edge portion is placed incontact with the surface of the object to impart directionalflexibility. The thickness and shape of the edge portion may be selectedto control the amount and direction of deformation. Generally, thoseportions of the edge portion that have the smallest edge portionthickness deform most readily. For example, where the edge portion istapered, those portions of the edge portion furthest from the baseportion (and having the smallest edge portion thickness) generallydeform most readily.

In the embodiment shown in FIG. 2, the edge portion 22 include a curvedportion 25 defining a curve. The curved portion 25 increases theflexibility of the edge portion 22, particularly in response to forcesapplied substantially parallel to the plane of the baffle, ensures abetter fit in certain areas of an assembly, and allows for bettersealing in a nominal condition for the baffle 10. In some instanceswhere the edge portion 22 includes a curved portion 25, at least part ofthe surface 36 of the edge portion 22 occupies a plane that liessubstantially perpendicular to a plane of the base portion 20. Theradius of curvature of the curved portion 25 may be selected to resultin a baffle 10 that best fits the assembly into which it is to beplaced.

The flexibility of edge portion 22 depends on the direction of forceapplied to the edge portion. When a force F is exerted on the edgeportion 22 in a direction substantially parallel to the plane of thebaffle 10, the edge portion 22 preferentially bends in the direction ofthe curve with no or minimal twisting or inversion of the edge portion22, such that it can still function to regulate air flow as intended.When a force F1 is applied in a direction opposite the curve, theflexibility of the edge portion 22 is less than when the force isapplied in a direction substantially parallel to the plane of the baffle10. When a force F2 is applied in the direction of the curve, theflexibility of the edge portion 22 is greater than when force is appliedin a direction substantially parallel to the plane of the baffle 10.

The edge portion preferentially deforms in the direction of the curve.For example, in the embodiment shown in FIG. 2, the curved portion 25defines a curve in direction A. When an object is placed in contact withthe edge portion 22, and a force F is applied to the edge portion 22 ina direction substantially parallel to the base portion 20, the edgeportion 22 preferentially deforms in the direction of the curve, asindicated by the arrow D. The extent of deformation, and the forceapplied by the edge portion 22 against the object, increases as thedistance between the object and the junction 38 decreases.

A baffle 10 as illustrated in FIGS. 1 and 2 may yield better sealingowing to the thinning of the edge portion, which can lead to increasedflexibility of the sealing edge. As illustrated in FIG. 3, the edgeportion 22 contacts a mating component 40 from the second end 26 and upits length to form a nominal interface 32. The length of the nominalmating interface is signified by d3. If the components of the assemblymove such that the baffle 10 is forced closer to the mating component40, such motion may give rise to a compensation condition. In thecompensation condition, a larger fraction of the edge portion 22 meetsthe mating component 40, such that a compensation interface 34 isderived, with an interface length of d4, greater than nominal interfacelength d3. The curved portion 25 of the sealing edge portion 22 leads toa condition in which the baffle 10 is still able to seal without causinga crash condition and disruption of the air regulation activity of thebaffle 10.

A baffle 10 as constructed in accordance with the embodiment illustratedin FIGS. 1 and 2 may act to increase the unidirectionality of sealingagainst a mating component. The curved portion 25 has a bias such thateven under conditions of increased duress, the baffle 10 will continueto seal against a mating element, due to the flexibility and shape ofthe edge portion 22. The tapered portion 30 can result in a decrease inthe flexural modulus of the baffle 10 between the junction 38 and thesecond end 26. Such a construction improves initial deflection, and dueto the taper and to the bias of the curve, the more the edge portion 22is pushed, the more it bends in the direction it is pushed, as opposedto adopting a failure state in which the relatively thin edge portioninverts or twists, thereby leading to a condition in which air flow isregulated incorrectly.

FIGS. 5-7 illustrate alternative embodiments of baffles constructed inaccordance with the principles of the present disclosure. In theembodiment illustrated in FIG. 5, a baffle 110 includes a base portion120 from which an edge portion 122 steps down in thickness at step 150.Thus, in the embodiment illustrated in FIG. 5, the first major surface111 a is substantially continuous, but the second major surface 111 b isnot. The edge portion 120 may extend away from the step 150 to secondend 126, and in doing so, may include a tapered portion 130 such thatthe thickest portion of the edge portion 122 is closest the step 150,and the thinnest portion is closest second end 126. In anotherembodiment, the edge portion 122 may have a substantially constantthickness along its entire length. The baffle 110 in this embodiment hasa curved portion 125 in the edge portion 122 to act as a seal, and has aunitary construction. Like the embodiment shown in FIG. 2, theflexibility of edge portion 122 depends on the direction of forceapplied to the edge portion. When a force is exerted on the edge portion122 in a direction substantially parallel to the plane of the baffle110, the edge portion 122 preferentially bends in the direction of thecurve with no or minimal twisting or inversion of the edge portion 122,such that it can still function to regulate air flow as intended. When aforce is applied in a direction opposite the curve, the flexibility ofthe edge portion 122 is less than when the force is applied in adirection substantially parallel to the plane of the baffle 110. When aforce is applied in the direction of the curve, the flexibility of theedge portion 122 is greater than when force is applied in a directionsubstantially parallel to the plane of the baffle 110.

The baffle 210 illustrated in FIG. 6 does not have a curve in its edgeportion 222; rather, the base portion 220 and the edge portion 222together combine to make a substantially continuous top surface 260which extends from the first end 224 to the second end 226. The sealingedge 268 is substantially perpendicular to the top surface 260. In thisembodiment, the edge portion 222 is thinner than the base portion 220and the junction is a step 250. The edge portion 222 may or may not betapered. The flexibility of edge portion 222 depends on the direction offorce applied to the edge portion. When a force is exerted on the edgeportion in a direction substantially parallel to the plane of the baffle210, the flexibility of the edge portion 222 is less than when the forceis applied at an angle to the plane of the baffle 210.

The baffle 310 of FIG. 7 is similar to the baffle 210 of FIG. 6, but inthis case the junction is not a step; rather, the edge portion 322tapers from junction 338 to second end 326. Such a design may bedesirable in a number of air flow regulation or gap fillingapplications, including hood seals, side seals, beauty seals, and thelike. Like the embodiment shown in FIG. 6, the flexibility of edgeportion 322 depends on the direction of force applied to the edgeportion. When a force is exerted on the edge portion in a directionsubstantially parallel to the plane of the baffle 310, the flexibilityof the edge portion 322 is less than when the force is applied at anangle to the plane of the baffle 310.

In the designs above, the base portion 20/120/220/320 of respectivebaffle 10/110/210/310 is relatively rigid or inflexible, whereas theedge portion 22/122/222/322 is relatively flexible. In certainembodiments, the flexibility of the edge portion may be derived from itslower overall thickness, when compared to the base portion. Thus, thebase portion 20/120/220/320 may have a first flexural modulus, and theedge portion 22/122/222/322 may have a second flexural modulus which isless than the first flexural modulus. A baffle with a tapering edgeportion may have progressively decreasing flexural moduli along itslength as traced away from the junction and toward the second end of thebaffle. A baffle of such construction may be favorable for meetingtolerances, such as the 3-5 mm tolerances required by many automotivemanufacturers for sealing applications.

The physical properties of a baffle constructed in accordance withprinciples of the present invention are further illustrated by theresults of straight-edge compression/deflection testing. In the testsillustrated in FIGS. 8-10, a force was applied to a two-inch long sampleof a baffle, in a direction parallel to the plane of the baffle, tocause deflection of the material with a magnitude of up to about 10millimeters. A deflection plate was placed in contact with the edge ofthe baffle, without causing deflection of the baffle, and was movedtoward the baffle, in a direction parallel to the plane of the baseportion of the baffle, to cause deflection of the baffle. The graphs inFIGS. 8-10 depict the force applied to the baffle as a function of thedisplacement of the plate from its original position

In FIG. 8, a component having a uniform thickness and a straight edge issubjected to such a test, yielding a curved profile that bears out amaxium force associated with the deflection of 0.50 kilonewton (kN). Asshown in FIG. 8, the force required for deflection increased to amaximum at about 0.06 inches of displacement of the plate and thendecreased upon further displacement of the plate, indicating a failureof the material when 113 pound-feet of energy were applied to the edge.

By contrast, the sample tested in FIG. 9 is a tapered element similar tothe baffle of FIG. 7. The taper reduces the maximum force applied toaffect a deflection of about 0.22 kN, with about 50 pound-feet requiredupon a 0.4 inch displacement of the plate from its original position.

Finally, a curved taper (similar to the baffle structure of FIGS. 1-4)was subjected to the same test. The results, as shown in FIG. 10,demonstrate that far less force is required to affect deflection of thebaffle with this shape, resulting in a maximum force applied of 0.02 kNduring the trial, and about 4.5 pound-feet of energy upon a 0.40 inchdisplacement of the plate from its original position. The forceincreased as the displacement of the plate from its original positionincreased. Taken together, a tapered portion in the edge portion of abaffle can be seen to impart increased flexibility and pliability to thecomponent, avoiding a failure condition, and further increases inflexibility and pliability were observed when the tapered portioncomprised as a curved portion.

As will be appreciated by one of skill in the art, a baffle of suchconstruction may be used for a number of different applications. Abaffle may be used to regulate air incoming to a radiator, such asthrough a fascia opening of an automobile. The baffle may also be usedas a side baffle. Other uses include shields around headlights,recirculation baffles, weather stripping, and beauty seals (under hood),among others. Depending on the size of the vehicle or other assembly,the scale of the baffle, including the length, width, and thickness ofthe base portion; length, width, and thickness of the edge portion;angle of taper; and other dimensions may be customized to fill gaps andmeet tolerances for a variety of different assemblies.

Instead of being made of a relatively rigid component attached to arelatively soft component, the baffle 10 as depicted in FIG. 1 has aflexible edge portion 22 and a relatively rigid base portion 20 due tothe change in thickness in the component, even if made of a singlematerial, the change in thickness being provided such as by the taper 30illustrated in FIG. 2. The edge portion 22 may be a sort of livinghinge, and may represent a soft lip for forming a seal. The relativeflexibility of edge portion 22 may further improve sealing by allowingthe sealing edge to conform to the component against which it is to formthe seal, thereby compensating for any structural imperfections in themating surface.

The present disclosure also relates to a method of making a baffle forregulating air flow around an object, comprising injecting a singlematerial in a molten state into a mold and allowing the material tosolidify to form the baffle. This process is known as “single shotinjection molding.” The foregoing method may be used to make any of thebaffles described herein.

Unlike conventional baffles that are currently on the market, theillustrated baffles 10/110/210/310 can be made by a one-step, singleshot injection molding and have a unitary construction. As a result, thebaffle 10/110/210/310 may be made of a single material. Further, thepart may be constructed without an extrusion step, and may not involvetime-consuming and costly post processing steps, such as bending orsonic welding.

An injection molded baffle 10/110/210/310 can be constructed from anumber of different materials. Pliable polymers that can be used forinjection molding workflows may be used for such a baffle. Among thesepolymers are polypropylene. In one embodiment, the baffle may beconstructed of a polypropylene-based material, such as an ENDURAPRENE,sold by GDC, Inc. A baffle according to the present disclosure may alsobe made of a thermoplastic elastomer, or a thermoplastic vulcanizate, orany other material suitable for injection molding.

In constructing the baffle 10/110/210/310, a material is selected andinjected in a molten state into a mold. The material is then allowed tosolidify, which forms the baffle. The mold includes cavities which allowfor the creation of a base portion and an edge portion. As has beendescribed, the base portion has a base portion thickness, and the edgeportion has an edge portion thickness that is less than the base portionthickness. The design described herein advantageously allows for asingle-shot workflow and avoids laborious, time-consuming, and expensivesteps.

While the present invention has been described in terms of preferredembodiments, it will be understood, of course, that the invention is notlimited thereto since modifications may be made to those skilled in theart, particularly in light of the foregoing teachings.

What is claimed is:
 1. A baffle for regulating air flow around anobject, the baffle comprising: a base portion, and an edge portion forcontacting a surface of the object, the base portion and the edgeportion being of unitary construction, the base portion having a baseportion thickness, and the edge portion having an edge portion thicknessthat is less than the base portion thickness such that the edge portionis capable of deforming to mate with the surface of the object while thebase portion remains substantially rigid; wherein the baffle includes afirst end and a second end, wherein the first end and the second end areseparate from each other and the baffle has a length extendinglongitudinally between the first and the second end, and wherein theedge portion extends longitudinally along at least a portion of thelength of the baffle.
 2. The baffle of claim 1, further comprising firstand second major surfaces and a junction between the base portion andthe edge portion, wherein the first and second major surfaces aresubstantially continuous at the junction.
 3. The baffle of claim 1,further comprising first and second major surfaces and a junctionbetween the base portion and the edge portion, wherein the base portionhas a base portion thickness at the junction, and the edge portion hasan edge portion thickness at the junction that is less than the baseportion thickness, such that the first or second major surface comprisesa step down at the junction.
 4. The baffle of claim 3, wherein the edgeportion has a substantially uniform edge portion thickness.
 5. Thebaffle of claim 1, wherein the edge portion is tapered such that theedge portion thickness comprises a first edge portion thickness proximalto the base portion and a second edge portion thickness distal to thebase portion that is less than the first edge portion thickness.
 6. Thebaffle of claim 1, wherein the base portion has a substantially uniformbase portion thickness.
 7. The baffle of claim 1, wherein the edgeportion preferentially deforms in a defined direction when the edgeportion is placed in contact with the surface of the object.
 8. Thebaffle of claim 7, wherein the edge portion comprises a curved portion,the curved portion defining a curve.
 9. The baffle of claim 8, whereinthe edge portion preferentially deforms in the direction of the curve.10. The baffle of claim 1, wherein the edge portion thickness is about20% to about 75% of the base portion thickness.
 11. The baffle of claim10, wherein the edge portion thickness is about 30% of the base portionthickness.
 12. The baffle of claim 1, wherein the baffle is made by asingle shot injection molding process.
 13. The baffle of claim 1,wherein the baffle is constructed from polypropylene.
 14. The baffle ofclaim 1, wherein the baffle is a radiator baffle.
 15. The baffle ofclaim 1, wherein the unitary structure of the baffle is formed byinjection molding.
 16. A baffle for regulating air flow around anobject, the baffle comprising: a base portion, and an edge portion forcontacting a surface of the object, the base portion and the edgeportion being of unitary construction, the base portion having a baseportion thickness, and the edge portion having an edge portion thicknessthat is less than the base portion thickness such that the edge portionis capable of deforming to mate with the surface of the object while thebase portion remains substantially rigid; wherein the base portionthickness and edge portion thicknesses are defined between first andsecond major surfaces of the baffle wherein the edge portion comprises acurved portion, the curved portion defining a curvature having a convexshape in a first radial direction and a concave shape in a second radialdirection that is opposite first radial direction wherein the edgeportion includes a straight portion extending from the curved portion,the first major surface extends along the straight portion, and at leasta portion of the first major surface extending along the straightportion is substantially perpendicular to a portion of the first majorsurface extending along the base portion.
 17. A baffle for regulatingair flow around an object, the baffle comprising a base portion and anedge portion for contacting a surface of the object, the base portionand the edge portion being of unitary construction, wherein the edgeportion is more flexible than the base portion such that the edgeportion is capable of deforming to mate with the surface of the objectwhile the base portion remains substantially rigid, wherein the edgeportion extends longitudinally between opposing first and second endsthereof.
 18. The baffle of claim 17, wherein the base portion has afirst flexural modulus, and the edge portion has a second flexuralmodulus that is less than the first flexural modulus.
 19. The baffle ofclaim 18, wherein the second flexural modulus is about 10% to about 95%of the first flexural modulus.
 20. The baffle of claim 17, wherein theunitary structure of the baffle is formed by injection molding.